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EP3768770B1 - Polyamide-imide binder for lithium ion battery - Google Patents

Polyamide-imide binder for lithium ion battery Download PDF

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Publication number
EP3768770B1
EP3768770B1 EP19712177.5A EP19712177A EP3768770B1 EP 3768770 B1 EP3768770 B1 EP 3768770B1 EP 19712177 A EP19712177 A EP 19712177A EP 3768770 B1 EP3768770 B1 EP 3768770B1
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Prior art keywords
imide
lipai
mol
polyamide
lithiated
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German (de)
English (en)
French (fr)
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EP3768770A1 (en
Inventor
Bryan Benson
R William TILFORD
Maurizio Biso
Christine HAMON
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Solvay Specialty Polymers USA LLC
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Solvay Specialty Polymers USA LLC
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
    • C08G73/10—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C08G73/14—Polyamide-imides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • H01M4/622—Binders being polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
    • C08L79/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C08L79/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/043—Processes of manufacture in general involving compressing or compaction
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/133—Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/134—Electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1393—Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1395—Processes of manufacture of electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/362—Composites
    • H01M4/364—Composites as mixtures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/386—Silicon or alloys based on silicon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H01M4/587—Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H01M4/625—Carbon or graphite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/027—Negative electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/028—Positive electrodes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention generally relates to lithiated polyamide-imide (LiPAI) polymers and their use as binders in negative electrodes for lithium ion batteries.
  • LiPAI lithiated polyamide-imide
  • PVDF polyvinylidene fluoride
  • binders based on polyacrylic acid (PAA), and carboxymethyl cellulose with styrene butadiene (CMC-SBR) have been studied, however they are brittle and have been found to create failure points within the binder matrix itself.
  • PAI Polyamide-imides
  • NMP N-methyl-2-pyrrolidone
  • US 2012/0088150 is generally directed to an electrode including a PAI-based binder for a lithium-ion secondary battery where a 1,3-benzenediamine peak is not observed when a composition including components extracted from the electrode by a solvent capable of dissolving the polyamideimide (PAI)-based binder is analyzed by pyrolysis-gas chromatography.
  • PAI polyamideimide
  • US 2015/0044578 (EI DU PONT DE NEMOURS AND CO.) is directed to binder precursor compositions containing certain PAIs for use in cathodes of lithium-ion batteries.
  • the reference generally discloses that acid sites in the unimidized or partially imidized binder precursor compositions can optionally be exchanged with cations such as lithium by contact, preferably with a non-aqueous solution of lithium salt, but no specific amounts are provided.
  • trimellitic anhydride monoacid chloride TMAC
  • PMDA non-lithiated pyromellitic dianhydride
  • ODA oxydianiline copolymer
  • JP 2013-089437, A discloses a binder material for the anode of a lithium-ion battery which, in some embodiments, can include a PAI and a lithium salt.
  • the reference provides examples of a solution including a PAI, a negative electrode active material, and a lithium salt; however, the PAI is highly imidized and the binder solutions are non-aqueous.
  • US 8,734,989 is generally directed to a negative electrode for a rechargeable lithium battery including a high-strength binder layer that is distinct from a negative active material layer to reduce the expansion rate of the electrode and improve cycle-life.
  • the high-strength binder can include a lithium salt in addition to a polymer selected from a long list of diverse polymers.
  • One of the polymers is generically described as an "amide-imide-based polymer;” however, the reference states that the high strength binder must have a crystallinity of at least 10% and a glass transition temperature (Tg) of not more than 100°C, and no PAI is exemplified.
  • US 2017/0155151 discloses water-soluble lithiated polyamic acids for use in binders for lithium-ion batteries to prevent a decrease in initial efficiency.
  • This reference does not disclose PAIs, which have a different chemical structure and properties.
  • the lithiated polyamic acids described are highly imidized, have an acid equivalent of less than 300 g/eq., have a molecular weight greater than 10,000 g/mol, and are prepared specifically with lithium hydroxide.
  • PAI binders for negative electrodes that are soluble in low cost and environmentally-friendly solvents such as water, and that preferably achieve high cycle stability without the requirement of high temperature curing.
  • US2009/136851 discloses a negative electrode comprising a non-carbon-based active material, a lithium salt having an oxalatoborate structure, and a high-strength polymer binder, which may be selected from polyamide imides, polyimides, polyacrylonitrile, carboxy methyl cellulose, cross-linked copolymers of polyacrylic acid and carboxy methyl cellulose, and combinations thereof.
  • EP3297083 pertains to a lithium ion secondary battery having a positive electrode comprising a lithium nickel composite oxide as a positive electrode active material and a separator consisting of one or more layers selected from polyimide layer, polyamide layer, the battery having a low self-discharge failure rate even after long term storage.
  • FIG. 1 is a plot illustrating the capacity retention of the full coin-cell batteries of Examples E11 and E12 and Comparative Examples C13 to C17.
  • LiPAI lithiated polyamide-imide
  • exemplary embodiments are directed to a LiPAI; a method of making the LiPAI; an electrode-forming composition comprising the LiPAI, an electrode active material, optionally at least one electro-conductive additive, and water; a method of making a negative electrode with the electrode-forming composition; and a lithium-ion battery comprising the negative electrode.
  • LiPAI Lithiated Poly(amide imide)
  • lithiumated polyamide-imide means any polymer comprising :
  • the floating amide bond indicates that the amide can be bonded to either of the closest carbons to the floating amide bond on the ring.
  • each formula represents both
  • recurring units R imide in the LiPAI are selected from at least one recurring unit of formula :
  • recurring units R amic acid in the LiPAI are selected from at least one recurring unit of formula :
  • recurring units R Li salt in the LiPAI are selected from at least one recurring unit of formula : , and
  • the recurring units R imide , R amic acid , and R Li salt in the LiPAI are respectively units of formulae :
  • recurring units R Li salt in the LiPAI are units of formula :
  • the recurring units R imide , R amic acid , and R Li salt in the LiPAI are respectively units of formulae :
  • the recurring units R imide , R amic acid , and R Li salt in the LiPAI are respectively units of formulae :
  • the LiPAI comprises more than one, for example two, of each of recurring units R imide , R amic acid , and R Li salt . Accordingly, in some aspects the LiPAI comprises :
  • the LiPAI includes less than 50 mol%, preferably less than 49 mol.%, 45 mol.%, 40 mol.%, 30 mol.%, 20 mol.%, 10 mole.%, 5 mol.%, 2 mol.%, 1 mol.% of the R imide recurring units. In some embodiments, the LiPAI is free of recurring units R imide .
  • the LiPAI includes less than 70 mol.%, preferably less than 60 mol.%, 50 mol.%, 40 mol.%, 30 mol.%, 20 mol.%, 10 mol.%, 5 mol.%, 2 mol.%, 1 mol.% of recurring units R amic acid .
  • the LiPAI includes at least 30 mol.%, 35 mol.%, 40 mol.%, 45 mol.%, 50 mol.%, 60 mol.%, 70 mol.%, 80 mol.%, 90 mol.%, 95 mol.%, 99 mol.% of recurring units Ru salt .
  • the mole ratio, R imide / (R amic acid + R Li salt ) is 1.0 or less, preferably 0.9, 0.8. 0.7, 0.6, 0.5, 0.4. 0.3, 0.2, 0.1 or less.
  • the mole ratio, R Li salt / (R imide + R amic acid ) is 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 or more.
  • the mole ratio, R Li salt / (R imide + R amic acid ) is preferably greater than 2, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 95, 99.
  • the amount of recurring units R amic acid ranges from 0 to 50 mol.%, and the amount of recurring units R Li salt ranges from 50 to 100 mol.%.
  • Determination of the relative amounts of recurring units R amic acid , and R Li salt in the LiPAI can be performed by any suitable method.
  • the amount of recurring units R imide (degree of imidization) can be assessed by NMR
  • the amount of recurring units R amic acid , and R Li salt can be assessed by NMR, elemental analysis, or titration.
  • the LiPAI has an acid equivalent greater than 300 grams per equivalent (g/eq) of acid.
  • the LiPAI has an acid equivalent greater than 325 g/eq, more preferably greater than 350 g/eq, and most preferably at least 375 g/eq or more.
  • the LiPAI is preferably water soluble.
  • water soluble or “soluble in water” means that at least 99 wt.% of the LiPAI, based on the total weight of the LiPAI, dissolves in deionized water to form a homogenous solution at 23°C with moderate stirring.
  • the LiPAI has a number average molecular weight (Mn) of at least 1,000 g/mol, preferably at least 2,000 g/mol, more preferably at least 4,000 g/mol. In some embodiments, the LiPAI has a number average molecular weight (Mn) of at most 10,000 g/mol, preferably at least 8,000 g/mol, more preferably at least 6,000 g/mol.
  • the LiPAI detailed above may be used as in the preparation of a binder for negative electrodes in lithium-ion batteries as described below.
  • LiPAI Lithiated Poly(amide imide)
  • Exemplary embodiments are also directed to a method of making the LiPAI described above.
  • polyamide-imide means any polymer comprising : 0 to 50 mol.% of at least one recurring unit R imide of formula : and 50 to 100 mol.% of at least one recurring unit R amic acid of formula : provided that recurring units R imide and R amic acid collectively represent more than 50 mol.%, preferably at least 60 mol.%, 75 mol.%, 90 mol%, 95 mol%, 99 mol.% of recurring units in the PAI, and Ar and R are as defined above.
  • recurring units R imide in the PAI are selected from at least one recurring unit of formula :
  • recurring units R amic acid in the PAI are selected from at least one recurring unit of formula :
  • the recurring units R imide and R amic acid in the PAI are respectively units of formulae :
  • the recurring units R imide , and R amic acid in the PAI are respectively units of formulae :
  • the recurring units R imide , and R amic acid in the PAI are respectively units of formulae :
  • Polyamide-imide polymers are available from Solvay Specialty Polymers USA, L.L.C. under the trademark, TORLON ® PAI.
  • the PAI includes less than 50 mol%, preferably less than 49 mol.%, 45 mol.%, 40 mol.%, 30 mol.%, 20 mol.%, 10 mole.%, 5 mol.%, 2 mol.%, 1 mol.% of the R imide recurring units. Most preferably the PAI is free of recurring units R imide .
  • the PAI includes at least 50 mol.%, preferably at least 60 mol.%, 70 mol.%, 80 mol.%, 90 mol.%, 95 mol.%, 99 mol.%, and most preferably 100 mol.% of recurring units R amic acid .
  • the PAI detailed above may be used as in the preparation of LiPAI as described above.
  • PAI copolymers can be manufactured according to known methods in the art. For example, processes for preparing PAI polymers are disclosed in detail in British Patent No. 1,056,564 , U.S. Pat. No. 3,661,832 and U.S. Pat. No. 3,669,937 .
  • PAI copolymers can be manufactured by a process including the polycondensation reaction between at least one acid monomer chosen from trimellitic anhydride and trimellitic anhydride monoacid halides and at least one comonomer chosen from diamines and diisocyanates.
  • the mol ratio of the at least one acid monomer to the comonomer is 1:1.
  • trimellitic anhydride monoacid chloride TMAC is preferred :
  • the acid monomers can exist in either an imide form or an amic acid form.
  • the comonomer can comprise one or two aromatic rings.
  • the comonomer is a diamine. More preferably, the diamine is selected from the group consisting of 4,4'-diaminodiphenylmethane (MDA), 4,4'-diaminodiphenylether (ODA), m-phenylenediamine (MPDA), and combinations thereof:
  • MDA 4,4'-diaminodiphenylmethane
  • ODA 4,4'-diaminodiphenylether
  • MPDA m-phenylenediamine
  • Example 1 An example of making a TMAC-ODA copolymer is described below in Example 1.
  • LiPAIs can be prepared from the PAI copolymers by neutralizing amic acid groups with a lithium salt. Therefore, in some aspects, the invention includes a method of lithiating a PAI comprising contacting the PAI with a lithium salt in a solvent.
  • the lithium salt can be any salt of lithium capable of neutralizing amic acid groups.
  • the lithium salt is selected from the group consisting of lithium carbonate, lithium hydroxide, lithium bicarbonate, and combinations thereof, preferably lithium carbonate.
  • the lithium salt is free of lithium hydroxide.
  • the solvent can be any solvent capable of dissolving the lithium salt and the resulting LiPAI.
  • the solvent is selected from at least one of water, NMP, and alcohols, such as, for example, methanol, isopropanol, and ethanol.
  • the solvent includes less than 5 wt.%, preferably less than 2 wt.%, preferably less than 1 wt.% of NMP. More preferably, the solvent is free of NMP. Most preferably, the solvent is water.
  • the concentration of the lithium salt in the solvent ranges from 3 to 30 wt.%, preferably from 5 to 30 wt.%, more preferably 10 to 30 wt.%, based on the total weight of the solvent and the lithium salt.
  • the concentration of the lithium salt in the solvent provides at least 1.5 eq., 2 eq., 2.5 eq., 3 eq., 4, eq of lithium to acid groups. In some embodiments, the concentration of the lithium salt in the solvent provides at most 5 eq., preferably at most 4, eq. of lithium to acid groups.
  • the method further includes heating the solution of the lithium salt and the PAI (or LiPAI) to a temperature ranging from 50°C to 90°C, preferably from 60°C to 80°C, most preferably from 65°C to 75°C, preferably for a time ranging from 15 min to 6 hours, preferably 1 to 2 hours.
  • the method further includes lowering the pH of the LiPAI obtained as above detailed by adding to the reaction mixture after lithiation at least one source of acid, for example, as a mineral acid or as an organic acid such as acetic acid, formic acid, oxalic acid, benzoic acid, or as an acid generating species, such as a polymer having acidic sites.
  • at least one source of acid for example, as a mineral acid or as an organic acid such as acetic acid, formic acid, oxalic acid, benzoic acid, or as an acid generating species, such as a polymer having acidic sites.
  • the concentration of the LiPAI in the solution preferably ranges from 1 to 20 wt.%, preferably 5 to 15 wt.%, most preferably 5 to 10 wt.%, based on the total weight of the LiPAI and the solvent.
  • the LiPAI can be isolated as a solid from the lithiating solution and optionally stored for later use.
  • the solid LiPAI can also be dissolved (or redissolved) in water to prepare the aqueous electrode-forming composition described below.
  • the solution including the LiPAI is an aqueous solution that can be used directly, optionally with further dilution with water, in preparing the electrode-forming composition as described below.
  • the LiPAI can be desirably incorporated into an aqueous electrode-forming composition for negative electrodes of lithium-ion secondary batteries.
  • the electrode-forming composition comprises the LiPAI as described above, an electrode active material, optionally at least one electro-conductive additive, and water.
  • the electrode-forming composition is preferably in the form of an aqueous dispersion, preferably a homogeneously-dispersed aqueous dispersion.
  • the electrode active material comprises a carbon-based material and a silicon-based material.
  • the carbon-based material may be, for example, graphite, such as natural or artificial graphite, graphene, or carbon black. These materials may be used alone or as a mixture of two or more thereof.
  • the carbon-based material is preferably graphite.
  • the silicon-based material may be one or more selected from the group consisting of silicon, alkoxysilane, aminosilane, silicon carbide and silicon oxide.
  • the silicon-based material is silicon.
  • the optional electro-conductive additive may be selected from carbonaceous materials such as carbon black, graphite fine powder, carbon nanotubes, graphene, or fiber, or fine powder or fibers of metals such as nickel or aluminum.
  • the optional electro-conductive additive is preferably carbon black. Carbon black is available, for example, under the brand names, Super P ® or Ketjenblack ® . When present, the electro-conductive additive is different from the carbon-based material described above.
  • the electrode-forming composition (and/or the electrode described below) includes an excess amount of lithium salt ranging from 1.5 to 5 eq., preferably 2 eq. to 5 eq., 2.5 eq. to 5 eq., 3 eq. to 4 eq., to acid groups.
  • the electrode-forming composition of the invention can contain at least one thickener; when present, the amount of thickener (also designated as rheology modifier) is not particularly limited and generally ranges between 0.1 and 10% wt, preferably between 0.5 and 5% wt, with respect to the total weight of the composition.
  • the thickener is generally added in order to prevent or slow down the settling of the powdery electrode material from the aqueous composition of the invention, while providing appropriate viscosity of the composition for a casting process.
  • suitable thickeners include, notably, organic thickeners such as partially neutralized poly(acrylic acid) or poly(methacrylic acid), carboxylated alkyl cellulose like carboxylated methyl cellulose and inorganic thickeners such as natural clays like montmorillonite and bentonite, manmade clays like laponite and others like silica and talc.
  • organic thickeners such as partially neutralized poly(acrylic acid) or poly(methacrylic acid)
  • carboxylated alkyl cellulose like carboxylated methyl cellulose
  • inorganic thickeners such as natural clays like montmorillonite and bentonite, manmade clays like laponite and others like silica and talc.
  • the electrode-forming composition can be used in a method for making a negative electrode.
  • the method comprises:
  • contacting at least one surface of the metal substrate with the electrode forming composition includes casting, printing, or roll-coating the electrode forming composition on at least one surface of the metal substrate.
  • the metal substrate is generally a foil, mesh or net made from a metal, such as copper, aluminum, iron, stainless steel, nickel, titanium or silver.
  • the compression step (iii) may include calendering to achieve a target porosity and density for the negative electrode.
  • the dried electrode forming material on the metal substrate is hot pressed at a temperature ranging from 25°C to 130°C, preferably about 60°C.
  • the preferred target porosity for the negative electrode ranges from 15% to 40%, preferably from 25% to 30%.
  • the porosity of the negative electrode is calculated as the complementary to unity of the ratio between the measured density and the theoretical density of the electrode, where :
  • Some embodiments are directed to negative electrodes obtained by the method as described above.
  • the negative electrode preferably comprises, based on the total weight of the electrode :
  • the negative electrode includes 0.5 to 5 wt.%, preferably 0.5 to 3 wt.% of the LiPAI, based on the total weight of the electrode.
  • the negative electrode includes 20 to 50 wt.%, preferably 30 to 50 wt.% of the silicon-based material.
  • the negative electrode of the invention is uncured.
  • uncured means that the LiPAI (e.g., in the electrode or electrode-forming composition) has not been exposed to a curing temperature of greater than 150°C.
  • the LiPAI in the uncured electrode may have a number average molecular weight of at most 10,000 g/mol, preferably at most 9,000 g/mol, 8,000 g/mol, 7,000 g/mol.
  • the negative electrode of the invention is a cured.
  • cured means that the LiPAI (e.g., in the electrode or electrode-forming composition) has been exposed to a curing temperature of greater than 150°C, preferably from 150°C to 300°C.
  • the LiPAI in the cured electrode may have a number average molecular weight greater than 8,000 g/mol, preferably greater than 10,000 g/mol.
  • the LiPAI having the molecular weights described above are more easily processed than are polymers of higher molecular weight.
  • the Applicant has surprisingly found that the negative electrodes of the present invention, in particular the uncured negative electrodes, exhibit significantly greater capacity retention than negative electrodes using comparative negative electrode binders.
  • the negative electrode of the invention is particularly suitable for use in lithium-ion in secondary batteries, which can be prepared by standard methods known to those of skill in the art.
  • an embodiment of the invention is directed to a lithium ion secondary battery comprising the negative electrode of the present invention together with a positive electrode, and electrolyte, and a separator.
  • the battery of the invention exhibits a percent capacity retention based on the initial capacity of the battery of at least 85%, preferably at least 90%, after 50 charge/discharge 10h/10h cycles with positive cut off of 1.5 V and negative cut off of 0.05V.
  • the inventive battery exhibits a 2% or less change in the percent capacity retention (based on the initial capacity of the battery) after 50 of the charge/discharge cycles described above, as compared with after 25 the charge/discharge cycles.
  • ODA monomer (60.0 g, 0.3 moles) was charged into a 4-neck jacketed round-bottom flask fitted with overhead mechanical stirrer. NMP (250 mL) was charged to the flask and the mixture was cooled to 10 °C with mild agitation under a nitrogen atmosphere. The flask was fitted with a heated addition funnel to which TMAC (64.0 g, 0.3 moles) was charged and heated to a minimum of 100 °C. The molten TMAC was added to the solution of diamine in NMP at a rate sufficient not to exceed 40 °C with vigorous agitation. Once the addition was complete, external heating was applied to maintain 35-40 °C for 2 hours.
  • Example 2 TMAC-ODA (50-50) Copolymer - 5 Wt.% Polymer and 3 eq. Lithium
  • Example 3 TMAC-ODA (50-50) Copolymer - 5 Wt.% Polymer and 1.5 eq. Lithium
  • Example 4 TMAC-ODA (50-50) Copolymer - 5 Wt.% Polymer and 4 eq. Lithium
  • Example 5 TMAC-ODA (50-50) Copolymer - 5 Wt.% Polymer and 5 eq. Lithium
  • Example 6 (TMAC-ODA) 90 (TMAC-MPDA) 10 PAI Copolymer - 5 Wt.% Polymer and 3 eq. Lithium
  • Example 7 Torlon ® PAI AI50 - 5 Wt.% Polymer and 3 eq. Lithium
  • An aqueous composition was prepared by mixing 20.16 g of a 6.2 wt.% solution of a LiPAI obtained in one of Examples 2 to 8, in water, 6.09 g of deionized water, 23.5 g of silicon/graphite, and 0.25 g of carbon black. The mixture was homogenized by moderate stirring in planetary mixer for 10 min and then mixed again by moderate stirring for 2h.
  • a negative electrode was obtained by casting the binder composition thus obtained on a 20 ⁇ m thick copper foil with a doctor blade and drying the coating layer in an oven at temperature of 60°C for about 60 minutes. The thickness of the dried coating layer was about 90 ⁇ m. The electrode was then hot pressed at 60°C in a roll press to achieve target porosity (30%). The resulting negative electrode had the following composition : 94 wt.% of silicon/carbon, 5 wt.% of LiPAI and 1 wt.% of carbon black. Electrodes E1, E2, E3, E4, E5, E6, E7 were prepared accordingly.
  • a negative electrode was prepared following the same procedure as detailed above, with the solution of LiPAI of Example 2, and was then cured under vacuum at about 210° C for 30 min and at about 260°C for additional 30 min to obtain a cured negative electrode.
  • Torlon ® PAI AI50 was first made water-soluble by neutralizing its amic acid groups with butyldiethanolamine. An aqueous composition was prepared by mixing 19.44 g of a 9 wt.% solution of the Torlon ® PAI AI50 in 17.31 g of deionized water, 32.9 g of silicon/carbon, and 0.35 g of carbon black.
  • the mixture was homogenized by moderate stirring in a planetary mixer for 10 min and then mixed again by moderate stirring for 2h giving a binder composition.
  • a negative electrode was obtained by casting the binder composition on a 20 ⁇ m thick copper foil with a doctor blade and drying the coating layer in an oven at temperature of 60°C for about 60 minutes. The thickness of the dried coating layer was about 90 ⁇ m. The electrode was then hot pressed at 60°C in a roll press to achieve target porosity (30%).
  • the negative electrode had the following composition : 94 wt.% of silicon/carbon, 5 wt.% of the PAI and 1 wt.% of carbon black.
  • NMP composition was prepared by mixing 25.00 g of a 5 wt.% solution of Torlon ® PAI 4000T in NMP, 1.25 g of NMP, 23.5 g of silicon/carbon and 0.25 g of carbon black. The mixture was homogenized by moderate stirring in planetary mixer for 10 min and then mixed again by moderate stirring for 2h giving a binder composition.
  • a negative electrode was obtained by casting the binder composition on a 20 ⁇ m thick copper foil with a doctor blade and drying the coating layer in an oven at temperature ramp from 80°C to 130°C for about 60 minutes.
  • the thickness of the dried coating layer was about 90 ⁇ m.
  • the electrode was then hot pressed at 90°C in a roll press to achieve the target porosity (30%).
  • the negative electrode had the following composition : 94 wt.% of silicon/carbon, 5 wt.% of the PAI and 1 wt.% of carbon black.
  • An aqueous composition was prepared by mixing 29.17 g of a 2 wt.% solution of CMC, in 5.25 g of deionized water, 32.9 g of silicon/carbon and 0.35 g of carbon black. The mixture was homogenized by moderate stirring. After about 1h of mixing, 2.33 g of SBR suspension was added to the composition and mixed again at low stirring for 1h, to give a binder composition.
  • a negative electrode was obtained by casting the binder composition on a 20 ⁇ m thick copper foil with a doctor blade and drying the coating layer in an oven at temperature of 60°C for about 60 minutes. The thickness of the dried coating layer was about 90 ⁇ m. The electrode was then hot pressed at 60°C in a roll press to achieve target porosity (30%).
  • the negative electrode had the following composition : 94 wt.% of silicon/carbon, 1.66 wt.% of CMC, 3.33 wt.% of SBR, and 1 wt.% of carbon black.
  • Electrode E11 was thus obtained.
  • An aqueous composition was prepared by mixing 5.2 g of a PAA aqueous solution (35% w/w), 30.2 g of deionized water, 34.2 g of silicon/graphite, and 0.36 g of carbon black. The mixture was homogenized by moderate stirring in planetary mixer for 10 min and then mixed again by moderate stirring for 2h to give a binder composition.
  • a negative electrode was obtained by casting the binder composition on a 20 ⁇ m thick copper foil with a doctor blade and drying the coating layer in an oven at temperature of 60°C for about 60 minutes. The thickness of the dried coating layer was about 90 ⁇ m. The electrode was then hot pressed at 60°C in a roll press to achieve target porosity (30%).
  • the negative electrode had the following composition : 94 wt.% of silicon/carbon, 5 wt.% of PAA, and 1 wt.% of carbon black.
  • Electrode E12 was thus obtained.
  • Lithium coin cells (CR2032 type, 20 mm diameter) were prepared in a glove box under an Ar gas atmosphere by punching a small disk of the electrode prepared according to Examples 8-10 and Comparative Examples 11-14 together with lithium metal as a counter and reference electrode.
  • the electrolyte used in the preparation of the coin cells was a standard 1M LiPF 6 solution in Selectilyte TM LP 30, with 2 wt.% of VC and 10 wt.% of F1EC additive; polyethylene separators (commercially available from Tonen Chemical Corporation) were used as received.
  • each of the two cells was galvanostatically cycled at a constant current rate of C/10 - D/10 with positive cut off of 1.5V and negative cut off of 0.05V.
  • Table 1 shows the example (or comparative example) number for the batteries tested, the corresponding negative electrode, the amount of equivalents of lithium used during preparation of the LiPAI (or PAI), the solvent that was used in the electrode-forming composition, and the capacity retention results at both 25 and 50 charge/discharge cycles shown as raw capacity and percent capacity of initial capacity.
  • Electrodes 1 and 7 were each surprisingly found to exhibit excellent capacity retention after both 25 and 50 cycles. And even more surprisingly, Electrode 1, representing an uncured LiPAI, registered significantly higher capacity retention than the comparative examples and was nearly unchanged even after 50 cycles.
  • Electrode 3 was found to exhibit satisfying capacity retention, far better than the comparative examples wherein electrodes prepared by aqueous compositions were used in the battery.
  • Comparative Example 3 which used a SBR/CMC binder, an 85% of initial capacity was observed after 25 cycles; however capacity was dramatically degraded after 50 cycles as shown in Figure 1 .

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